Method and apparatus for cladding elongated structural members

ABSTRACT

A method and apparatus for the attachment of sheet cladding and other thin surfaces to structural frame members such as in space frames and other lattice structures. A batten assembly may be either partially integrated into an elongated structural member or attached by fasteners. A batten receiver provides a pair of sheet margin receiving channels and a fastener guide channel. The batten receiver may be integrated into the surface of the elongated structural member which for example, may be a tubular member or I-beam. The mating batten comprises shoulders which are essentially congruent to the receiving channels. Between the shoulders, an elongated recess mates with a pair of guide walls in the receiver. A fastener such as a metal screw having a cutting tip, may be installed through the recess and the guide channel and into the wall of the elongated structural member to provide secure connection of the batten members to one another. The shoulder and receiving channels receive the sheet margins in compressive engagement. The invention herein permits the cladding of elongated structural members in an aesthetically pleasing flush mounting configuration which allows for water run-off from the cladding sheet surfaces. The invention also provides an advantageous hidden round seal configuration which while also being aesthetically more pleasing, is also more protective of the seal integrity. This invention also provides batten attachments of sheet cladding and other thin surfaces to elongated members of a tubular cross-section.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of U.S. Ser. No. 10/087,639filed Mar. 1, 2002 and claims priority therefrom.

FIELD OF THE INVENTION

[0002] The present invention relates generally to the field ofstructural design and more specifically to attachment of claddingsurfaces to elongated structural members such as for creating largevolume enclosures.

BACKGROUND ART

[0003] An example of conventional dome construction is illustrated inU.S. Pat. No. 3,909,994 to Richter. This construction employs structuralframe members arranged in a polygonal pattern forming framed openings.These openings are covered with thin sheet material to provide anenclosure without openings. The edge margins of the sheet material arelocked and retained by retainer members which incorporate flanged gasketelements to seal the sheets to the structural frame members. The flangedstructural members and the sheet margins are connected to hub members.The sheets are connected to the structural members by bar portions whichclamp down on the sheet margins curved to form flanges. Because the barportions extend above the sheet surfaces, each sheet is surrounded by anelevated perimeter and exposed gaskets. This configuration is typical ofprior art structures where a cladding sheet is affixed to a system offrame members with flanges.

[0004] One significant disadvantage of such prior art is that theelevated perimeter around respective sheet surfaces creates a barrier towater drainage thereby promoting collection of rain water and the like.This promotes corrosion, mildew, dirt accumulation and other forms ofdeterioration which can be detrimental to the function and appearance ofthe structure.

[0005] Another significant disadvantage is the limitation of the use ofthe batten and receiver cladding system to flanged structural membersonly. This limitation leaves out elongated members with a tubularcross-section.

[0006] Another disadvantage is the exposure of the sealing gasket to theambient environment above the frame members. This often means exposureto the outside elements such as extreme temperatures and moistureincluding pooled rain water as noted above. Such exposure can reducegasket effectiveness, permit leakage and require frequent and costlymaintenance. Moreover, the prior art sealing gasket is irregularlyshaped and specifically configured.

[0007] Based upon the foregoing, it can be readily observed that thereis a need for an improved way of affixing cladding surfaces to tubularand flanged elongated structural members to overcome the deficiencies ofthe prior art. More specifically, it would be a significant improvementto provide a flush-mounted cladding connection apparatus which wouldobviate elevated sheet perimeters that would otherwise interfere withwater drainage. It would be a major improvement to provide a batten andreceiver cladding connection for elongated members with a tubularcross-section. It would also be a welcome improvement to provide adesign where the elastomeric seal or gasket is a simple round or O-ringtype cross-section and is not exposed to the outside elements so thatthe gasket life is greatly improved. These improvements would beparticularly useful in a frame structure which employs tubularstructural members such as those disclosed in U.S. Pat. No. 5,956,917 toReynolds, a co-inventor hereof.

SUMMARY OF THE INVENTION

[0008] The present invention meets the aforementioned needs and providesthe desired improvements for the attachment of sheet cladding and othernon-load bearing thin surfaces to structural frame members such as inspace frames and other lattice structures. The present invention mayalso be used advantageously to provide ceilings, or inverted roofs wherethe structural members are located above an underlying uninterruptedsurface. The invention may also be provided in certain embodiments foruse in connecting aluminum sheeting to steel structural members withoutsubstantial contact between the dissimilar metals. Other embodimentsfind utility where thermal or electrical isolation is needed betweenstructural members and cladding or other sheet material.

[0009] A principal feature of the preferred embodiments of the inventioncomprises a unique batten configuration which may be either partiallyintegrated into an elongated structural member or attached by fasteners.A batten receiver provides a pair of sheet margin receiving channels anda fastener guide channel. The batten receiver may be integrated into thesurface of the elongated structural member which for example, may be atubular member or I-beam. The mating batten comprises shoulders whichare essentially congruent to the receiving channels. Between theshoulders, an elongated recess mates with a pair of guide walls in thereceiver. A fastener such as a metal screw having a cutting tip, may beinstalled through the recess and the guide channel and into the wall ofthe elongated structural member to provide secure connection of thebatten members to one another. The shoulder and receiving channelsreceive the sheet margins in compressive engagement. Retention stripscommonly referred to as a “cat's paw” may be optionally provided on themating shoulder and channel surfaces to provide added security inretaining the sheet therebetween. The mating batten is uniquelyconfigured to be flush with the cladding sheet to obviate water run-offbarriers and to provide an aesthetically pleasing interface. Moreover,the mating batten provides a seal receptacle for receiving an elongatedelastomeric O-ring seal that is isolated from the exposed surface of thebatten so that the seal is not exposed to the environment. It will thusbe seen hereinafter, that the present invention provides a number ofunique and highly advantageous features with the principal object ofovercoming the aforementioned deficiencies of the prior art. Morespecifically, the invention herein permits the cladding of elongatedstructural members in an aesthetically pleasing flush mountingconfiguration which allows for water run-off from the cladding sheetsurfaces. The invention also provides a batten and receiver claddingconnection for elongated members with a tubular cross-section. Theinvention also provides an advantageous hidden round seal configurationwhich while also being aesthetically more pleasing, is also moreprotective of the seal integrity and does not need to be uniquelyconfigured for this particular apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The aforementioned objects and advantages of the presentinvention, as well as additional objects and advantages thereof, will bemore fully understood hereinafter as a result of a detailed descriptionof a preferred embodiment when taken in conjunction with the followingdrawings in which:

[0011]FIG. 1 is a three-dimensional view of an I-beam comprising apartially integrated batten design in accordance with a preferredembodiment of the invention;

[0012]FIG. 2 is a cross-sectional view of the improved I-beam of FIG. 1;

[0013]FIG. 3 is a cross-sectional view of a tubular structural membercomprising a partially integrated batten design similar to that of FIG.1 but also illustrating the mating batten, cladding and a fastener of apreferred embodiment;

[0014]FIG. 4 is similar to FIG. 3 but showing the batten fully securedto the tubular member by the fastener and engaging the cladding sheetmargins;

[0015]FIG. 5 is a three-dimensional view of the tubular member/claddingarrangement of FIG. 4 with the cladding and batten partially removed;

[0016]FIG. 6 is a cross-sectional view of an alternative embodiment ofthe invention employing a non-integrated or “split batten” wherein bothbatten members are separated from the underlying structural member andconnected to the structural member by a standoff device affixed to boththe batten receiver and the structural member;

[0017]FIG. 7 is a cross-sectional view of the split batten upperportion;

[0018]FIG. 8 is a cross-sectional view of the split batten lowerportion;

[0019]FIG. 9 is a three dimensional view of the embodiment of FIG. 6with the cladding, batten and tubular structural member partiallyremoved; and

[0020]FIG. 10 is a three-dimensional view of yet another embodiment ofthe invention which is particularly usefully for thermally orelectrically isolating the cladding from the elongated structuralmember.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0021] Referring initially to FIGS. 1 and 2, it will be seen that in afirst embodiment 10 of the invention, an I-beam 12 has integratedtherewith a cladding batten receiver 14. The receiver comprises a pairof shoulders 16 and a pair of guide walls 18. A receiving channel 20 isformed between each shoulder and an adjacent guide wall. The channel 20is preferably U-shaped having an inclined planar side 17 leading intothe curved or arched channel. This shape facilitates receiving a gentlybent and curved cladding sheet margin as will become more evidenthereinafter. The pair of guide walls 18 form a fastener guide channel 22between them for receiving and guiding a fastener as will be also mademore clear below.

[0022] Referring to FIGS. 3,4 and 5, it will be seen that a firstalternative embodiment 25 is similar to the embodiment of FIGS. 1 and 2,but implemented in a tubular elongated member 26 instead of flangedelongated members as found in the prior art. More specifically, a battenreceiver 28 is integral to the tube wall and comprises shoulders 30 andguide walls 32 and has a pair of receiving channels 34. Similarly, abatten 36 has a pair of rounded ridges 38 which are substantiallycongruent to channels 34. Batten 36 also comprises a pair of sealreceptacles 40 each designed to retain an elongated O-ring elastomericseal 42. A fastener 46 is received in a guide channel 44 and extendsthrough the wall of the tubular structural member 26. When the batten 36is compressed into engagement with the batten receiver 28 by thefastener 46 as depicted in FIG. 4, the margins of cladding sheets 45 aretrapped therebetween with the elastomeric seal 42 compressed against thesheet. Moreover, as also seen in FIG. 4 as well as FIG. 5, the uppersurface of batten 36 lies substantially flush (i.e., in co-planarrelation) with cladding sheets 45 to permit unobstructed water run-offwithout any elevated barriers such as found in relevant prior art.

[0023] Another alternative embodiment 55 is shown in FIGS. 6 through 9.This embodiment is particularly useful where the elongated member andthe batten 3 components and cladding are made of dissimilar metals.

[0024] For example, if the tubular structural member 56 were made ofsteel, an aluminum batten assembly 58 can be affixed by means of astandoff stud 66 having a shoulder 68. Moreover, the cladding 64 may bealuminum sheeting. Thus, this embodiment permits aluminum cladding ofsteel structural members. The batten assembly 58 of this embodiment issubstantially similar to that of the FIG. 5 embodiment with one majordistinction. Batten receiver 60 is an independent component and is notan integral part of the tubular member 56. In all other respects, thebatten assembly 58 is identical to that of the integral embodiments.Specifically, a batten 62 has a pair of shoulders 63 which aresubstantially congruent to channels 61 of batten receiver 60. A guidechannel 67 is provided to direct a fastener into stud 66.

[0025]FIG. 9 also depicts a technique for splicing cladding members toone another without attachment to a structural member. For example, ifit were required to join two cladding sheets to fill a space betweenstructural members, the non-integral batten 60/62 of FIGS. 6-9, wouldenable such joining.

[0026] Yet another embodiment 75 is illustrated in FIG. 10. Thisembodiment is particularly useful where it is desired to eitherthermally or electrically isolate the cladding 70 from the tubularstructural member 72. The lower batten member 74 may be made of aselected insulating material such as a thermally and/or electricallynon-conductive composite. The upper batten member 76 is secured by meansof fasteners 77 and the lower batten member 74 is secured by fasteners78 through apertures 80 and into the structural member 72.

[0027] Having the benefit of learning of a number of embodiments of theinvention, it will be understood that still other embodiments as well asvariations in those illustrated are contemplated. By way of example,while structural members comprising I-beams and circular tubes have beendisclosed, it should be apparent that the invention may be employed fordirect cladding of other shaped structural members, such as those havinga triangular, square, rectangular or irregular cross-section orcombinations thereof. Furthermore, while the disclosed embodimentsillustrate generally planar cladding, the invention does not require usewith flat sheets, but may be used with more complex surfaces such asconvex, concave or non-uniform variations in shapes and thicknesses.

[0028] Accordingly, those having skill in the relevant art will perceivevarious modifications and additions which may be readily made to thedisclosed versions. However, such modifications and additions may bewithin the scope of the invention which is limited only by the appendedclaims and their equivalents.

We claim:
 1. An apparatus for affixing cladding sheets directly toelongated structural members, the sheets having shapeable marginportions; the apparatus comprising: a batten assembly having a receiveraffixed to said structural member for receiving said margin portions anda mating batten for correspondingly engaging said receiver for retainingsaid margin portions in a locked relation with said structural member;said assembly being substantially co-linear with said structural member;said mating batten being substantially co-planar with said claddingsheets adjacent said structural member; wherein said batten assembly isspaced from said structural member by at least one standoff studconnected to both said assembly and to said structural member.
 2. Theapparatus recited in claim 1 wherein said cladding sheets and saidstructural members are made of dissimilar metals.
 3. The apparatusrecited in claim 1 wherein said dissimilar metals are aluminum andsteel.
 4. The apparatus recited in claim 1 wherein said batten assemblyextends substantially the entire length of said structural member. 5.The apparatus recited in claim 1 wherein said batten assembly is made ofa material which is substantially non-conductive to electrical energy.6. The apparatus recited in claim 1 wherein said batten assembly issubstantially non-conductive to thermal energy.
 7. An apparatus forcladding elongated structural members having a tubular cross-section;the apparatus comprising: a batten assembly having a first portionaffixed to a radial wall of at least one of said tubular members and asecond portion selectively engaging said first portion in at leastpartial congruent relation to trap cladding therebetween in compressiverelation; said batten assembly being configured to be substantiallyco-planar with said cladding adjacent said at least one tubular member;wherein said batten assembly is spaced from said structural member by atleast one standoff stud connected to both said assembly and to saidstructural member.
 8. The apparatus recited in claim 7 wherein saidbatten assembly is made of a material which is substantiallynon-conductive to electrical energy.
 9. The apparatus recited in claim 7wherein said batten assembly is substantially non-conductive to thermalenergy.
 10. A method for cladding elongated structural members; themethod comprising the steps of: a) providing a batten assembly having abatten receiver and a mating batten, the batten receiver having at leastone channel for receiving the margin of a cladding sheet, the matingbatten having a shoulder that is substantially congruent to saidchannel; b) affixing said batten receiver to one said structural member;c) bending said sheet margin to conform to said channel; d) placing saidsheet margin in said channel so that said cladding sheet will be flushwith said batten assembly; e) trapping said margin in said channel bypositioning said shoulder of said mating batten in said channel; and f)fastening said mating batten to said batten receiver; wherein step a)comprises the step of making said batten assembly out of a materialwhich is substantially non-conductive to at least one of thermal andelectrical energy.
 11. The method recited in claim 10 wherein step b)comprises the step of connecting said receiver to said one structuralmember by using a standoff stud to space said receiver from saidstructural member.